Liquid crystal display device comprising first and second electric field distortion units and the passivation layer is directly contacted on the first substrate and method of fabricating the same

ABSTRACT

A liquid crystal display device includes: a first substrate and a second substrate; a gate line and a data line on the first substrate that cross each other to define a pixel region; a pixel electrode in the pixel region; a thin film transistor at the crossing of the gate and data lines, and connected to the pixel electrode; at least one first electric field distortion unit in the pixel electrode to control a liquid crystal director by electric field distortion; a second electric field distortion unit between the pixel electrode and the first substrate; and a layer of liquid crystal molecules between the first and second substrates.

The present invention claims the benefit of Korean Patent ApplicationNo. 029982/2005 filed in Korea on Apr. 11, 2005, which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a display device, and moreparticularly, to a liquid crystal display device. Although the presentinvention is suitable for a wide scope of applications, it isparticularly suitable for forming multi-domains in each of the pixels ofa liquid crystal display device.

2. Description of the Related Art

One of the types of liquid crystal displays (LCDs) typically used inmost recent years is a twisted nematic (TN) mode LCD. The structure of aTN mode LCD includes two substrates on which respective electrodes areformed and a layer of liquid crystal molecules between the twosubstrates. The liquid crystal molecules within the layer have a longshape oriented parallel to each of the two substrates with a constantpitch, and are spirally twisted. Thus, a liquid crystal director can beoriented when a voltage is applied across the electrodes on the twosubstrates.

The TN mode LCD has been increasingly used and researched because itprovides excellent color reproducibility. However, since light is notcompletely cut off during the off-state in a TN mode LCD, a contrastratio is poor. Further the contrast ratio varies with a viewing angle.Accordingly, it is difficult to present a stable image because halftonebrightness varies as the viewing angle is varied. In other words, theappearance of an image depends on the angle at which the LCD is viewed.

To address image variation due to different angles of viewing, varioustypes of LCDs have been proposed to present a stable image over a widerange of viewing angles. For example, an in-plane switching mode (IPS)LCD having two electrodes disposed on one plane such that a transverseelectric field is generated across the electrodes to reliably cut offlight during the off-state has been developed. In another example, afilm-compensated mode LCD has been developed in which a compensationfilm compensates for image variation due to change in the angle in whichthe LCD is viewed. In yet another example, a vertical alignment (VA)mode LCD has been developed that uses a vertical alignment layer and anegative liquid crystal with a negative dielectric anisotropy toreliably cut off light during the off-state.

The VA mode LCD is mainly classified into a multi-domain verticalalignment (MVA) mode LCD in which a plurality of domains are formed anda liquid crystal direction of each domain is different, and an advancedsuper-V (ASV) mode LCD in which a pixel electrode is divided into smallparts and a liquid crystal direction is controlled by a rib in a centralportion of the divided pixel electrode. The MVA mode LCD and the ASVmode LCD are configured such that the liquid crystal directors areopposite to each other to compensate for image variations due to changein the angle in which the LCD is viewed. Therefore, the MVA mode and ASVmode enable the LCD to present a consistent image throughout a widerange of viewing angles.

FIG. 1 is a plan view of the related art MVA mode LCD, and FIG. 2 is across-sectional view taken along the line I-I′ of FIG. 1. Referring toFIGS. 1 and 2, the related art MVA mode LCD includes an upper substrate21, a lower substrate 111 and a layer of liquid crystal moleculesinterposed therebetween. Herein, the lower substrate 11 includes a gateline 12 and a data line 15, which are respectively arranged in row andcolumn directions, and cross each other so as to define a pixel region.A pixel electrode 17 is formed in the pixel region. A thin filmtransistor (TFT) is formed in adjacent to a crossing of the gate line 12and the data line 15, and a plurality of first electric field distortionunits 33 is formed in a predetermined region of the pixel electrode 17for controlling a liquid crystal director through electric fielddistortion. The TFT is selectively switched by a scan signal of the gateline 12 so as to apply a data signal of the data line 15 to the pixelelectrode 17.

As shown in FIG. 1, the first electric field distortion unit 33 has theshape of a slit, which is formed by selectively removing a portion ofthe pixel electrode 17. Meanwhile, the TFT is configured with a gateelectrode 12 a extending from the gate line 12, a gate insulating layer16 on the gate electrode, a semiconductor layer 18 formed on the gateelectrode in a shape of an island, source/drain electrodes 19 and 15 athat extend from the data line 15, and the pixel electrode 17.

Although not illustrated in FIGS. 1 and 2, the lower substrate 11further includes a storage capacitor parallel to the gate line 12. Thestorage capacitor maintains a charged voltage in the liquid crystallayer while the TFT is turned off so that it prevents image quality fromdeteriorating.

The upper substrate 21 includes a black matrix 22 for preventing lightleakage, a color filter layer 23 of red, green and blue formed betweenthe black matrix layers 22 for displaying a color on a screen, a commonelectrode 24 stacked on the color filter layer 23 such that it isopposite to the pixel electrode 17 of the lower substrate 11, aplurality of second electric field distortion units 31 formed in apredetermined region of the common electrode 24 for controlling theliquid crystal director by the electric field distortion. Although it isillustrated in FIG. 1 that the second electric field distortion unit 31has the shape of a rib, which is formed by separately depositing adielectric material on the common electrode 24 followed by patterning aconductive material, the second electric field distortion unit 31 may beformed in a shape of a slit within the conductive material like thefirst electric field distortion unit 33.

As shown in FIG. 1, the first and second electric field distortion units33 and 31 are alternately arranged in the shape of oblique lines whichare parallel to each other, to thereby form multi-domains. However, incase of the related art VA mode LCD, it is necessary to perform adeposition process of a dielectric material on the upper substrate 21 aswell as patterning processes to pattern an ITO electrode to form thesecond electric field distortion unit 31 in the shape of a rib or slit,as shown in FIG. 2. Therefore, there is a drawback in that the number ofthe process inevitably increases the implementation of multi-domains ineach pixel region.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a liquid crystaldisplay device (LCD) and a method of fabricating the same thatsubstantially obviate one or more problems due to limitations anddisadvantages of the related art.

An object of the present invention is to reduce the number offabrication process steps for forming multi-domains in each of thepixels of a liquid crystal display device. and enhancing an apertureratio by structuring the LCD.

Another object of the present invention is to enhance an aperture ratioof multi-domains in each of the pixels of a liquid crystal displaydevice.

Additional advantages, objects, and features of the invention will beset forth in part in the description which follows and in part willbecome apparent to those having ordinary skill in the art uponexamination of the following or may be learned from practice of theinvention. The objectives and other advantages of the invention may berealized and attained by the structure particularly pointed out in thewritten description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with thepurpose of the invention, as embodied and broadly described herein,there is provided a liquid crystal display device including: a firstsubstrate and a second substrate; a gate line and a data line on thefirst substrate that cross each other to define a pixel region; a pixelelectrode in the pixel region; a thin film transistor at the crossing ofthe gate and data lines, and connected to the pixel electrode; at leastone first electric field distortion unit in the pixel electrode tocontrol a liquid crystal director by electric field distortion; a secondelectric field distortion unit between the pixel electrode and the firstsubstrate; and a layer of liquid crystal molecules between the first andsecond substrates.

In another aspect of the present invention, there is provided a liquidcrystal display device including: a first substrate and a secondsubstrate; a gate line and a data line on the first substrate that crosseach other to define a pixel region; a pixel electrode in the pixelregion; a thin film transistor in an intersection region of the gate anddata interconnections, and connected to the pixel electrode; at leastone electric field distortion unit between the pixel electrode and thefirst substrate such that the at least one electric field distortionunit divides the pixel electrode into two or more parts to control aliquid crystal director by electric field distortion; and a layer ofliquid crystal molecules between the first and second substrates.

In yet another aspect of the present invention, a method ofmanufacturing a liquid crystal display device having a first substrateand a second substrate includes: forming a gate line and a data line onthe first substrate that cross each other to define a pixel region;forming a pixel electrode in the pixel region; forming a thin filmtransistor at the crossing of the gate and data lines, and connected tothe pixel electrode; forming an electric field distortion unit betweenthe pixel electrode and the first substrate; and providing a layer ofliquid crystal molecules between the first and second substrates.

It is to be understood that both the foregoing general description andthe following detailed description of the present invention areexemplary and explanatory and are intended to provide furtherexplanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this application, illustrate embodiment(s) of the invention andtogether with the description serve to explain the principle of theinvention.

In the drawings:

FIG. 1 is a plan view of the related art MVA mode liquid crystal displaydevice (LCD);

FIG. 2 is a cross-sectional view taken along the line I-I′ of FIG. 1;

FIG. 3 is a plan view of an LCD according to an embodiment of thepresent invention;

FIG. 4 is a cross-sectional view taken along the line II-II″ of FIG. 3;

FIG. 5 is a plan view of an LCD according to another embodiment of thepresent invention; and

FIG. 6 is a cross-sectional view taken along the line III-III′ of FIG.5.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the preferred embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts.

FIG. 3 is a plan view of an LCD according to an embodiment of thepresent invention, and FIG. 4 is a cross-sectional view taken along theline II-II′ of FIG. 3. Referring to FIGS. 3 and 4, the MVA mode LCD inan embodiment of the present invention includes an upper substrate 121,a lower substrate 111 and a layer of liquid crystal molecules interposedtherebetween. The lower substrate 111 includes a gate line 112 and adata line 15, which are respectively arranged in a row direction and acolumn direction, and cross each other to define a pixel region. A pixelelectrode 117 is formed in the pixel region. A thin film transistor is(TFT) formed adjacent to the crossing of the gate line 112 and the dataline 115. A plurality of first electric field distortion units 133 isformed in a predetermined region of the pixel electrode 117 forcontrolling a liquid crystal director by electric field distortion, anda second electric field distortion unit 131 is formed and parallel tothe first electric field distortion unit 133. The TFT is selectivelyswitched by a scan signal of the gate line 112 so as to apply a datasignal from the data line 115 to the pixel electrode 117.

In embodiments of the present invention, both the first and secondelectric field units 131 and 133, which are used for formingmulti-domains, are formed on the lower substrate 111. More particularly,the first electric field distortion unit 133 is a series of slits formedby selectively removing portions of the pixel electrode 117, and thesecond electric field distortion unit 131 is a stepped portion 150obtained by forming at least one gate metal layer 151 between the pixelelectrode 117 and the lower substrate 111. As illustrated in FIG. 3, thefirst and second electric field distortion units 133 and 131 are in theshape of oblique lines alternately arranged and parallel to each other.The first electric field distortion unit 133 and the second electricfield distortion unit 131 form multi-domains in one pixel region.

The TFT includes a gate electrode 112 a extending from the gate line112, a gate insulating layer 152 formed on the gate electrode 112 a, asemiconductor layer 118 formed on the gate electrode in the shape of anisland, source/drain electrodes 115 a and 119, which extend from thedata line 115, and the pixel electrode 117. The TFT is formed by aprocess including three to five masking steps. In embodiments of thepresent invention, the stepped portion 150 of the second electric fielddistortion unit 131 is simultaneously formed during the formation of theTFT to implement the multi-domains in one pixel without additionalfabrication processes. More particularly, the stepped portion 150, whichis simultaneously formed with the TFT, includes a gate metal layer 151,a gate insulating layer 152, a semiconductor layer 153, a source/drainelectrode layer 155, and a passivation layer 157 stacked in sequence.The pixel electrode 117 is formed over the entire surface of the steppedportion 150.

The TFT can be formed with a three step masking process using a lift-offprocess having a high step. Further, since the same three step maskingprocess can form a stepped portion 150 of the second electric fielddistortion unit 131, it is suitable to implement the multi-domainbecause electric field distortion is effectively generated. In thealternative, the stepped portion 150 of the second electric fielddistortion unit 131 and the TFT can be formed with either a four or fivestep masking process. The TFT can be formed with a three step maskingprocess using a halftone mask or a diffractive mask.

The upper substrate 121 includes a black matrix 122 for preventing lightleakage, a color filter layer 123 of red, green and blue formed betweenthe black matrix layers 122 for displaying a color on a screen. A commonelectrode 124 stacked on the color filter layer 123 such that it isopposite to the pixel electrode 117 of the lower substrate 111. Unlikethe related art, an electric field distortion unit, such as a rib or aslit, is not formed on the upper substrate 121.

According to embodiments of the present invention, there are noadditional process for forming an electric field distortion unit, suchas a rib or a slit. In other words, it is not necessary to perform adeposition process of a dielectric material on the upper substrate or apatterning processes to form an electric field distortion unit on theupper substrate like in the related art. Instead, a stepped portion isformed on the lower substrate that acts as the electric field distortionunit such the multi-domains can be obtained without additionalfabrication processes.

Although not shown in FIGS. 3 and 4, the MVA mode LCD further includes avertical alignment layer on inside surfaces of the pixel electrode 117and the common electrode 124 for controlling the arrangement of theliquid crystal molecules in the liquid crystal layer of the MVA modeLCD. The MVA mode LCD employs liquid crystal molecules with a negativedielectric anisotropy. The major axis of each liquid crystal molecule isinitially arranged perpendicular to the lower substrate 111 usingalignment layers (not shown) on the upper and lower substrates 121 and111.

As shown in FIG. 4, each pixel region is divided into four regions(denoted as i, ii, iii and iv in FIG. 4) using the first and secondelectric field distortion units 131 and 133 formed on the lowersubstrate 111 to implement the multi-domains. In addition, the gatemetal layer 151, which is an element of the stepped portion 150 of thesecond electric field distortion unit 131, may constitute a storagecapacitor together with the pixel electrode 117 and the passivationlayer 157. That is, a storage capacitor is implemented by applying acommon voltage Vcom to the gate metal layer 151. Therefore, the storagecapacitor maintains a voltage across the layer of liquid crystalmolecules while the TFT is turned off so as to prevent the image qualityfrom deteriorating.

In the related art VA mode LCD, a linewidth of the gate line isincreased because the gate line is used as the lower electrode of thestorage capacitor. However, according to embodiments of the presentinvention, the storage capacitor may be formed in the center of thepixel and the linewidth of the gate line can be reduced. Because thelinewidth of the gate line can be reduced, the aperture ratio of the LCDcan be increased.

To implement the multi-domains in the related art TN mode LCD, severaldifferent methods can be employed, such as a method using a tiltdifference between the alignment layers of the upper and lowersubstrates, a multi-rubbing method or a photo-alignment method. Themethod using the tilt difference has a problem in that a large number ofprocess steps are required. The multi-rubbing method also has a problemof requiring a large number of process steps as well as causing a shadoweffect that reduces the aperture ratio. The photo-alignment method has ashortcoming in that alignment forces for aligning liquid crystalmolecules are weak such that reliability is poor.

FIG. 5 is a plan view of an LCD according to another embodiment of thepresent invention, and FIG. 6 is a cross-sectional view taken along theline III-III′ of FIG. 5. More specifically, a twisted nematic (TN) LCDis illustratively set forth in FIG. 5. In the TN mode LCD according toanother embodiment of the present invention, the electric fielddistortion unit is formed on the lower substrate such that the pixelregion is divided into at least two parts such that multi-domains can beimplemented. The electric field distortion unit is formed as a steppedportion 250 and is simultaneously formed with the TFT in each pixelregion.

Referring to FIGS. 5 and 6, the TN mode LCD according to anotherembodiment of the present invention includes an upper substrate 221, alower substrate 211 and a layer of liquid crystal molecules interposedtherebetween. The lower substrate 211 includes a gate line 212 and adata line 215 which are arranged in rows and columns and intersectedwith each other so as to define a pixel region, a pixel electrode 217formed in the pixel region, a TFT formed in an intersection region ofthe gate line 212 and the data line 215, at least one electric fielddistortion unit(s) 231 formed such that the pixel region is divided intoat least two parts for controlling a liquid crystal director throughelectric field distortion. The TFT is selectively switched by a scansignal of the gate line 212 so as to apply a data signal of the dataline 215 to the pixel electrode 217.

Herein, the electric field distortion unit 231 has a stepped portion 250obtained by forming a gate metal layer under the pixel electrode 217. Inan embodiment of the present invention shown in FIGS. 5 and 6, thestepped portion 250 of the electric field distortion unit 231 issimultaneously formed during the formation of the TFT to implement themulti-domains in a pixel region without additional fabricationprocesses. More particularly, the stepped portion 250, which issimultaneously formed with the TFT, includes a gate metal layer 251, agate insulating layer 252, a semiconductor layer 253, a source/drainelectrode layer 255, and a passivation layer 257 stacked in sequence.The pixel electrode 217 is formed over the entire surface of the steppedportion 250. As shown in FIG. 5, the electric field distortion unit 231is formed longitudinally in a central portion of the pixel region andparallel to the data lines 215 and 215′. As shown in FIG. 6, electricfield distortion occurs due to the step in the central region of thepixel region such the multi-domains occur between the pixel electrode217 and the data lines 215 and 215′.

The TFT includes a gate electrode 222 a extending from the gate line222, a gate insulating layer 152 formed on the gate electrode 222 a, asemiconductor layer 218 formed on the gate electrode in the shape of anisland, source/drain electrodes 215 a and 219, which extend from thedata line 215, and the pixel electrode 217. The TFT is formed by aprocess including three to five masking steps. In embodiments of thepresent invention, the stepped portion 250 of the second electric fielddistortion unit 231 is simultaneously formed during the formation of theTFT to implement the multi-domains in one pixel region withoutadditional fabrication processes.

The TFT can be formed with a three step masking process using a lift-offprocess having a high step. Further, since the same three step maskingprocess can form a stepped portion 250 of the second electric fielddistortion unit 131, it is suitable to implement the multi-domainbecause electric field distortion is effectively generated. In thealternative, the stepped portion 250 of the second electric fielddistortion unit 231 and the TFT can be formed with a four or five stepmasking process.

The upper substrate 121 includes a black matrix 122 for preventing lightleakage, a color filter layer 123 of red, green and blue formed betweenthe black matrix layers 122 for displaying a color on a screen. A commonelectrode 124 stacked on the color filter layer 123 such that it isopposite to the pixel electrode 117 of the lower substrate 111. Unlikethe related art, an electric field distortion unit, such as a rib or aslit, is not formed on the upper substrate 121

According to embodiments of the present invention, it is possible toeasily form the multi-domains in the respective pixel regions withoutany supplementary process by forming the stepped portion, which isformed on the lower substrate of the LCD, in a predetermined portion ofeach pixel region in a matrix. In the related art TN mode LCD, alinewidth of the gate line is increased because the gate line is used asthe lower electrode of the storage capacitor. However, according toembodiments of the present invention, the storage capacitor may beformed in the center of the pixel region and the linewidth of the gateline can reduced. Because the linewidth of the gate line can be reduced,the aperture ratio of the LCD can be increased. The shape of the steppedportion in the above embodiments are mere exemplary and is not limitedto those described above.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present invention. Thus,it is intended that the present invention covers the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A liquid crystal display device comprising: a first substrate and asecond substrate; a gate line and a data line on the first substratethat cross each other to define a pixel region; a pixel electrode in thepixel region; a thin film transistor at crossing of the gate and datalines, and connected to the pixel electrode; at least one first electricfield distortion unit in the pixel electrode to control a liquid crystaldirector by electric field distortion; a second electric fielddistortion unit between the pixel electrode and the first substrate,which the second electric field distortion unit is a stepped portionincluding a gate metal layer, a gate insulating layer, a semiconductorlayer, a source/drain electrode layer and a passivation layer; and alayer of liquid crystal molecules between the first and secondsubstrates, wherein the stepped portion of the second electric fielddistortion unit is simultaneously formed during the formation of thethin film transistor to implement a multi-domains in one pixel withoutadditional fabrication process, wherein the gate metal layer, the gateinsulating layer, a semiconductor layer and the source/drain electrodelayer of the stepped portion are patterned in a slit form and they arestacked in sequence, and wherein the passivation layer of the steppedportion is directly contacted on the source/drain electrode layerpatterned in the slit form and the first substrate of the pixel region.2. The liquid crystal display device according to claim 1, wherein thesecond electric field distortion unit is parallel to the first electricfield distortion unit.
 3. The liquid crystal display device according toclaim 1, wherein the first electric field distortion unit is a slit inthe pixel electrode.
 4. The liquid crystal display device according toclaim 1, wherein the gate metal layer, the passivation layer and thepixel electrode form a storage capacitor.
 5. The liquid crystal displaydevice according to claim 1, wherein the first and second electric fielddistortion units are alternately arranged parallel to each other asoblique lines to form multi-domains in the pixel region.
 6. The liquidcrystal display device according to claim 1, further comprising verticalalignment layers disposed on inside surfaces of the first and secondsubstrates for controlling the initial arrangement of the liquid crystalmolecules.
 7. The liquid crystal display device according to claim 1,wherein the liquid crystal display device is multi-domain verticalalignment mode.
 8. A method of manufacturing a liquid crystal displaydevice having a first substrate and a second substrate, comprising:forming a gate line and a data line on the first substrate that crosseach other to define a pixel region; forming a pixel electrode includingat least one first electric field distortion unit in the pixel electrodeto control a liquid crystal director by electric field distortion;forming a thin film transistor at crossing of the gate and data lines,and connected to the pixel electrode; forming a second electric fielddistortion unit between the pixel electrode and the first substrate,which the second electric field distortion unit is a stepped portionincluding a gate metal layer, a gate insulating layer, a semiconductorlayer, a source/drain electrode layer and a passivation layer; andproviding a layer of liquid crystal molecules between the first andsecond substrates, wherein the stepped portion of the second electricfield distortion unit is simultaneously formed during the formation ofthe thin film transistor to implement a multi-domains in one pixelwithout additional fabrication process, wherein the gate metal layer,the gate insulating layer, a semiconductor layer and the source/drainelectrode layer of the stepped portion are patterned in a slit form andthey are stacked in sequence, and wherein the passivation layer of thestepped portion is directly contacted on the source/drain electrodelayer patterned in slit form and the first substrate of the pixelregion.
 9. The method according to claim 8, further comprising: formingvertical alignment layers on inside surfaces of the first and secondsubstrates for controlling the initial arrangement of the liquid crystalmolecules.
 10. The method according to claim 8, wherein the forming thesecond electric field distortion occurs simultaneously with the forminga thin film transistor.
 11. The method according to claim 8, wherein thegate metal layer, the passivation layer and the pixel electrode form astorage capacitor.